Vehicle door preassembly, door manufacturing process, and door produced thereby

Abstract: A vehicle door (1) presenting a metal outer panel (2) defining a window opening (7); an inner cover panel (8) for covering the outer panel (2); a door lock mechanism (21); and a window regulator (15) for operating and guiding a sliding window (13) closing the window opening (7); at least the lock mechanism (21) and the window regulator (15) being connected to the cover panel (8) and defining, together with the cover panel (8), a preassembly (3) positively connected to the outer panel (2).

Description: The present invention relates to a preassembly for vehicle doors in general, and motor vehicle doors in particular. In general, a vehicle door comprises an outer panel with, in most cases, a bottom portion, and a top frame portion defining a window opening for a sliding window. In the traditional vehicle door, the bottom portion is normally fitted with a door lock mechanism, a window regulator for operating and guiding the sliding window, and the wiring for supplying the lock mechanism and window regulator, which are subsequently concealed by an inner cover panel. In recent times, to speed up on-line assembly, testing and revision of the door, the lock mechanism, window regulator and supply cables are preassembled off-line on a movable supporting frame to form a functional assembly which only later is fitted on-line to the bottom portion of the outer panel, followed by fitment of the window to the control slide of the window regulator and assembly of the finish cover panel. Though widely adopted, the above assembly process still remains relatively time-consuming and expensive, mainly due to the assembly line being supplied separately, not only with the preassembly, but also with other components such as the cover panel and window, and due to the fact that neither the preassembly as described above nor the other components are normally fittable to the outer panel fully automatically, e.g. by means of robots. EP 0 336 565 discloses a vehicle door comprising an inner and outer door panel, each of which is hinged to a vehicle body, and a door hardware which comprises a window regulator mechanism, a door latch and a door latch release handle each of which are directly connected to an outer surface of the inner door panel. It is an object of the present invention to provide a straightforward vehicle door preassembly designed to overcome the above drawbacks and which, in particular, is fittable automatically to the outer panel. According to the present invention, there is provided a vehicle door preassembly as defined in claim 1. The present invention also relates to a vehicle door manufacturing process. According to the present invention, there is provided a process for manufacturing a vehicle door as defined in claim 10. A non-limiting embodiment of the present invention will be described by way of example with reference to the accompanying drawings, in which: Figure 1 shows a side view of a vehicle door outer panel and, detached from the outer panel, a preferred embodiment of the preassembly according to the present invention; Figure 2 shows a side view, from inside, of the door formed by fitting the preassembly to the outer panel. Number 1 in the accompanying drawings indicates a vehicle door, in particular a motor vehicle door, comprising a preferably metal outer panel 2, and a preassembly 3 (Figure 1) fittable to outer panel 2. As shown in Figure 1, outer panel 2 comprises a substantially rectangular bottom portion 4 with two spaced parallel cross members 5; and a frame 6 connected integral with portion 4 with which it defines a window opening 7. The inner surface of outer panel 2 is fitted with a cover panel 8 preferably formed in one piece from plastic material, substantially of the same shape as outer panel 2, and forming part of preassembly 3. In the example shown, panel 8 comprises a substantially rectangular bottom portion 9 presenting a central cavity 10 (Figure 1) on one side, a pocket 10a (Figure 2) on the other, and which fits on to portion 4 of outer panel 2. Panel 8 also comprises a top frame portion 11 extending in contact with frame 6 with which it defines the window opening 12 of door 1. Window opening 12 is closed by a window 13 forming part of preassembly 3, extending between outer panel 2 and panel 8, and fitted in sliding manner to panel 8 via the interposition of a first seal 14 (Figure 2), and to outer panel 2 via a second known seal (not shown) also fitted to outer panel 2. Window 13 is moved in relation to outer panel 2 and between an open and closed position by a known window regulator 15 forming part of preassembly 3, housed inside cavity 10, and supported inside cavity 10 on a plate 16, the opposite end portions of which are connected integral with respective intermediate portions of portion 9. More specifically, window regulator 15 comprises a slide 36 connected integral with the bottom peripheral portion of window 13 and operated by a known link drive 17. Drive 17 is in turn operated by an electric motor 18, the supply cables 19 of which are fitted to plate 16 and terminate in respective terminals connected to the terminal board of a cable assembly 20 (shown partially in Figure 1) extending towards the central portion of the vehicle. Assembly 20 is fitted to panel 8, and is preferably embedded inside panel 8 when this is formed or during assembly of preassembly 3. As shown in Figure 1, plate 16 is also fitted with a known door lock mechanism 21 also forming part of preassembly 3 and comprising a lock 22 with a top lever for connection to the outside door handle (not shown), and a known power operated safety door lock device 23 with supply cables 24 also connected to panel 8 and connected in known manner to cable assembly 20. As shown in Figure 1, preassembly 3 of door 1 is fitted to outer panel 2 by means of a number of elastic appendixes 25 fitted to and spaced along the inner surface of portion 11 of panel 8, and each of which positively engages a respective seat or opening 26 formed in portion 6 of outer panel 2. Preassembly 3 is also fitted to outer panel 2 by means of a number of fastening elements 27 (Figure 2) extending through respective holes 28 in a peripheral portion of portion 9 of panel 8, and positively engaging - preferably clicking inside - respective holes 29 in a peripheral portion of portion 4 of outer panel 2. Door 1 as described above is produced by first forming preassembly 3 and then fitting it to outer panel 2. More specifically, preassembly 3 is formed by fitting window regulator 15 and lock mechanism 21 to plate 16; inserting plate 16 inside cavity 10 in panel 8 formed beforehand, for example, by molding; fitting plate 16 removably to portion 9 of panel 8; electrically connecting supply cables 19 and 24 of motor 18 and device 23 respectively to assembly 20 already embedded inside, and hence integral with, panel 8; fitting cables 19 and 24 to plate 16 or portion 9 of panel 8; and, finally, fitting window 13 to both panel 8, by fitting it on to respective seal 14, and to window regulator 15 by fitting the bottom portion of window 13 on to slide 36. Once assembled, preassembly 3 is picked up, preferably by means of a robot fixture (not shown) or by an operator, and positioned facing outer panel 2, and more specifically in such a position that each appendix 25 corresponds with a respective seat 26, and holes 28 correspond with holes 29. At this point, preassembly 3 is moved towards outer panel 2; panel 8 is pressed on to outer panel 2 so that appendixes 25 positively engage respective seats 26; and, still pressing panel 8 on to outer panel 2, fastening elements 27 are inserted inside respective holes 28 and driven into holes 29. Bottom portion 9 of panel 8 is thus connected removably to portion 4 to complete the bottom portion of door 1; while top portion 11 of panel 8 is connected removably to frame 6 with which it defines a channel for window 13, and at the same time covers frame 6 to complete the top portion of door 1. A pretested preassembly of the type described above thus provides for greatly simplifying assembly of the door and, more especially, for enabling a drastic reduction in on-line assembly, testing and revision time, by virtue of supplying the assembly line with no more than two parts, one consisting of metal outer panel 2, and the other of all the other, preassembled, working components of the door. Also, by virtue of supplying the assembly line with only two parts which are easily connectable to each other, this may be done using fully automatic robot fixtures, thus enabling a reduction in the skilled labour still required at present for assembling known doors. Clearly, changes may be made to door 1 as described and illustrated herein without, however, departing from the scope of the present invention. For example, panel 8 need not necessarily present portion 11 or the whole of portion 11; window 13 need not necessarily form part of the preassembly, and may be fitted to outer panel 2 in known manner and to respective slide 36 during fitment of preassembly 3 to outer panel 2; and changes may be made to elements 25 and 27 for connecting preassembly 3 to outer panel 2. Moreover, panel 8 need not necessarily present cavity 10 or pocket 10a, and window regulator 15 and door lock mechanism 21 may be housed in a cavity formed in outer panel 2, in which case, plate 16 may be dispensed with and portion 9 may be reinforced, for example, by means of ribs. Finally, as opposed to being embedded in panel 8, cable assembly 20 may simply be fitted to the surface of panel 8 using known fastening elements such as brackets or terminal strips screwed to or embedded in panel 8.

Claims: A vehicle door preassembly (3) fittable to an outer door panel (2) presenting a bottom portion (4) and a top frame (6) defining a window opening (7); the preassembly comprising at least a door lock mechanism (21) and a window regulator (15) for operating and guiding a sliding window (13) closing the window opening (7); electric actuating means (18) (23) for at least said window regulator (15) or said lock mechanism (21) and presenting respective supply cables (19) (24); and electric connecting means interposed between said supply cables (19) (24) and a cable assembly (20) extending towards a given portion of the vehicle; the preassembly also comprising an inner cover panel (8) for covering the outer panel (2) and in turn comprising at least a bottom portion (9) fittable to said bottom portion (4) of the outer panel (2); said lock mechanism (21) and said window regulator (15) being supported by to said cover panel (8); connecting means (25,27) being provided for positively connecting said preassembly (3) to said outer panel (2), characterized in that at least said actuating means (18, 23) for said window regulator (15) and said lock mechanism (21) are fitted to a common supporting element (16) in turn fitted to said cover panel (8). A preassembly as claimed in claim 1, characterized in that said door lock mechanism (21) and said window regulator (15) are fitted to the said common supporting element (16). A preassembly as claimed in Claim 1 o 2, characterized in that said cover panel (8) also comprises a top frame portion (11) fittable to said top frame (6) of the outer panel (2); said window (13) being fitted in sliding manner to said top frame portion (11) and being connected to the slide (36) of the window regulator (15). A preassembly as claimed in any of the foregoing Claims, characterized in that said cable assembly (20) is fitted to said cover panel (8). A preassembly as claimed in any of the foregoing Claims from 1 to 4, characterized in that said cable assembly (20) is at least partially embedded in said cover panel (8). A preassembly as claimed in any one of the foregoing Claims, characterized in that it also comprises a seal (14) fitted to said cover panel (8) and interposed between the cover panel (8) and said window (13). A preassembly as claimed in any one of the foregoing Claims, characterized in that said connecting means (25, 27) comprise fastening means arranged along the edge of said cover panel (8). A preassembly as claimed in Claim 7 characterized in that said fastening means (25) are fast-fit fastening means, and comprise a number of appendixes (25) integral with said cover panel (8) and each positively engaging a respective seat (26) formed in said outer panel (2). A preassembly as claimed in Claim 7, characterized in that said cover panel (8) comprises a number of first holes (28); and said fastening means comprise an equal number of fastening elements (27), each extending through a respective said first hole (28) and positively engaging a respective second hole (29) formed in the outer panel (2). A process for manufacturing a vehicle door (1) comprising an outer panel (2) presenting a bottom portion (4) and a top frame (6) defining a window opening (7); the process comprising stages consisting in forming a preassembly (3), and fitting the preassembly (3) to the outer panel (2) of the door (1); said preassembly (3) being formed using a cover panel (8) comprising at least a bottom portion (9) fittable to the bottom portion (4) of said outer panel (2), and by fitting said cover panel (8) with at least a door lock mechanism (21) and a window regulator (15) for operating and guiding a sliding window (13) closing said window opening (7); said preassembly comprising electric actuating means (18) (23) for at least said window regulator (15) or said lock mechanism (21) and presenting respective supply cables (19) (24); and electric connecting means interposed between said supply cables (19) (24) and a cable assembly (20) extending towards a given portion of the vehicle, characterized in that the formation of said preassembly (3) comprising a preliminary stage consisting in fitting at least said actuating means (18, 23) for said window regulator (15) and said lock mechanism (21) to a common supporting element (16), and subsequently fitting the common supporting element (16) to said cover panel (8). A process as claimed in Claim 10, characterized in that said cover panel (8) also comprises a top frame portion (11) similar to and fittable to said top frame (6); the formation of said preassembly (3) also comprising further stages consisting in fitting said window (13) in sliding manner to said top portion (11) of the cover panel (8), and connecting the window (13) to the slide (36) of said window regulator (15). A process as claimed in Claim 10 or 11, characterized in that the formation of said preassembly (3) comprises a further stage consisting in fitting said cable assembly (20) to said cover panel (8). A process as claimed in Claim 12, characterized in that said cable assembly (20) is fitted to said cover panel (8) by embedding at least part of the cable assembly (20) inside the cover panel (8). A process as claimed in any one of the foregoing Claims from 12 to 13, characterized in that the formation of said preassembly (3) comprises a further stage consisting in fitting said cover panel (8) with a seal (14) interposed between the cover panel (8) and said window (13). A process as claimed in any one of the foregoing Claims from 10 to 14, characterized in that connection of the preassembly (3) to the outer panel (2) comprises stages consisting in positioning the cover panel (8) in relation to the outer panel (2); and pressing the cover panel (8) on to the outer panel (2) so that a number of appendixes (25) integral with and arranged along the edge of the cover panel (8) positively engage respective seats (26) formed in the outer panel (2). A process as claimed in any one of the foregoing Claims from 10 to 14, characterized in that connection of the preassembly (3) to the outer panel (2) comprises stages consisting in positioning the cover panel (8) in relation to the outer panel (2); bringing the cover panel (8) into contact with the outer panel (2); and connecting the cover panel (8) to the outer panel (2) by means of a number of fastening elements (27) driven into the outer panel (2) and arranged along the edge of the cover panel (8). A vehicle door (1) comprising an outer panel (2) presenting a bottom portion (4) and a top frame (6) defining a window opening (7); and a preassembly (3) fitted to the outer panel (2); characterized in that the preassembly (3) is formed as claimed in any one of the foregoing Claims from 1 to 8.

Inventors: FILIPPI ALDO, FILIPPI, ALDO
Applicants: ATOMA ROLTRA SPA, ATOMA ROLTRA S.P.A.
Application year: 1994
Main classification: B60J5
IPC codes: B60J5